CONTENTS General ................................................. 4 TC51 Specifications .............................. 5 TC71 Specifications .............................. 6 TC92 Specifications .............................. 7 TC152 Specifications ............................ 8 TC301 Specifications ............................ 9 Hazard Alerts ........................................ 10 Sizing the Compactor ........................... 13 Typical Hydraulic Circuits ...................... 16 Installation ...
GENERAL BTI compactors are designed to mount on mini-excavators, backhoes and excavators. BTI compactors combine centrifical force, down pressure, and vibration to work as soil compactors or pile/sheet drivers. The compactor has 3 basic components: • Mounting Bracket: attaches the compactor to the carrier boom and is complete with adjustable mounting pins. • Rubber Isolators: act as suspension between the base and the mount & isolate the compactor forces from the carrier.
TC51 SPECIFICATIONS TC51L/FC TC51H/FC Impulse Force: 1,930 - 3,000 lb 875 - 1,360 kg 1,930 - 3,000 lb 875 - 1,360 kg Oil Flow Req'd: 7.2 - 12 USgpm 27.2 - 45 l/min 10.7 - 18 USgpm 40.4 - 68 l/min Cycles/Minute: 1,800 - 2,240 1,800 - 2,240 Hydraulic Connections: #8 JIC Male #8 JIC Male Minimum Tube I.D.: 1/2" 1/2" Operating Pressure: 920 - 1,135 psi 63 - 78 bar 700 - 860 psi 102 - 150 bar Base Plate Dimension: 12.5 x 28" 317.5 x 711 mm 12.5 x 28" 317.5 x 711 mm Compaction Area: 1.
TC71 SPECIFICATIONS TC71 TC71FC Impulse Force: 2,600 - 5,000 lb 1,179 - 2,268 kg 2,600 - 5,000 lb 1,179 - 2,268 kg Oil Flow Req'd: 11.7 - 16.3 US gpm 44.2 - 61.6 l/min 11.7 - 22 USgpm 44.2 - 83.2 l/min Cycles/Minute: 1,800 - 2,500 1,800 - 2,500 Hydraulic Connections: #12 JIC Male #12 JIC Male Minimum Tube I.D.: ¾" ¾" Operating Pressure: 1,200 - 2,000 psi 81 - 136 bar 1,200 - 2,000 psi 81 - 136 bar Base Plate Dimension: 15 x 31.5" 381 x 800 mm 15 x 31.
TC92 SPECIFICATIONS TC92 Impulse Force: 5,500 - 8,200 lb 2,494 - 3,719 kg Oil Flow Req'd: 20.6 - 25.2 US gpm 77.9 - 95.3 l/min Cycles/Minute: 1,800 - 2,200 Hydraulic Connections: #12 JIC Male Minimum Tube I.D.: ¾" Operating Pressure: 970 - 1,200 psi 67 - 83 bar Base Plate Dimension: 23 x 34.9" 584 x 886 mm Compaction Area: 4.3 sq ft 0.
TC152 SPECIFICATIONS TC152L TC152H Impulse Force: 11,130 - 16,630 lb 5,048 - 7,542 kg 11,130 - 16,630 lb 5,048 - 7,550 kg Oil Flow Req'd: 26.7 - 32.7 US gpm 100.9 - 123.6 l/min 37.4 - 45.7 US gpm 141.4 - 172.7 l/min Cycles/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male Minimum Tube I.D.: 1" 1” Operating Pressure: 1,600 - 1,964 psi 110 - 135 bar 1,190 - 1,460 psi 82 - 101 bar Base Plate Dimension: 28 x 45.7" 711 x 1161mm 28 x 45.
TC301 SPECIFICATIONS TC301L TC301H Impulse Force: 16,300 - 24,400 lb 7,406 - 11,066 kg 16,300 - 24,400 lb 7,406 - 11,066 kg Oil Flow Req'd: 37.4 - 45.7 US gpm 141.4 - 172.7 l/min 53.5 - 65.3 gpm 202.2 - 246.8 l/min Cycles/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male Minimum Tube I.D.: 1" 11/4” Operating Pressure: 1,480 - 1,820 psi 102 - 126 bar 1,080 - 1,330 psi 74 - 92 bar Base Plate Dimension: 34 x 48.4" 864 x 1229 mm 34 x 48.
HAZARD ALERTS Danger, Warning, and Caution are hazard alerts used in this manual and on the compactor decals to identify hazards on or near the carrier and compactor. Danger - Immediate hazards, which WILL result in severe personal injury or death if the proper precautions are not taken. Warning - Hazards or unsafe practices, which COULD result in personal injury or death if the proper precautions are not taken.
HAZARD ALERTS Do not operate the compactor with personnel in the immediate area of the carrier and compactor. Note and avoid all hazards and obstructions such as overhangs, ledges, slide areas, electrical lines, underground cables, water mains, gas lines, etc. When operating close to electrical lines, underground cables, water mains or gas lines, contact the responsible authority and request assistance.
HAZARD ALERTS Head Protection Foot Protection Eye Protection Hearing Protection Do not operate or service the compactor unless you are qualified. Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles. These can get caught in moving parts. Jewelry may also ground a live circuit. Know and use the protective equipment that is to be worn when operating or servicing the carrier.
SIZING THE COMPACTOR The compactor must be sized properly for both the carrier on which it will be mounted and the work to be done. Sizing the Compactor based on the Type of Work Most applications require the soil under a road or load bearing surface to be compacted to 95% or greater than the proctor density. This can be achieved with a compactor, provided the soil is the correct type and moisture. Uniform materials like clay and sand are difficult to compact.
SIZING THE COMPACTOR Always use a compactor sized to the carrier. A compactor that is too small for the carrier will damage the compactor, while a compactor too big will damage the carrier. Ensure you have the proper installation kit for attaching the compactor and that the carrier's hydraulic system meets the compactor flow and pressure requirements. The carrier that is selected to operate the compactor must have sufficient reach to compact the deepest area of the trench or excavation.
TYPICAL HYDRAULIC CIRCUITS To run, a compactor needs hydraulic flow in one direction within a working pressure range.
TYPICAL HYDRAULIC CIRCUITS Carrier with Auxiliary Circuit Often a carrier is equipped with an auxiliary control valve (see Figure 1), this valve can be adjusted to provide the correct amount of oil flow to the compactor. A pressure relief cartridge can also be installed to protect the hydraulic components. Make sure that oil is not routed back through the return port of this auxiliary valve. Instead, send the oil directly back to the tank, via the cooler and filter.
TYPICAL HYDRAULIC CIRCUITS Carrier without Auxiliary Circuit If the carrier does not have an auxiliary control valve (see Figure 2), a priority flow control valve must be installed to direct oil flow from the normal circuit to the compactor. The priority flow control valve is usually equipped with a flow adjustment and pressure relief. These auxiliary control valves often need a check valve on the regulated port to completely close the flow.
INSTALLATION There is no separate pressure adjustment on the compactor. The compactor's supply oil should be directed out the left side of the boom and the return line back on the boom's right side. A combination of hoses and steel tubing is recommended to keep the installation neat and cost effective. Hoses and tubes should be secured to the carrier boom with steel clamps. Attaching mounting clamps or bulkhead fittings to the ends of the tubes will prevent the tubes from sliding.
SETTING FLOW & PRESSURE For a compactor to operate properly it requires a specific oil flow and sufficient oil pressure. TC51L/FC: 1400 psi @ 7.2-12 USgpm Oil Flow & Oil Pressure (97 bar) @ (27.2-45.4 l/min) TC51H/FC: 1200 psi @ 10.7-18 USgpm (83 bar) @ (40.4-68 l/min) TC71: 1400 psi @ 11.7-16.3 USgpm (97 bar) @ (44.2-61.6 l/min) TC71FC: 1600 psi @ 11.7-22 USgpm (110 bar) @ (44.2-83.2 l/min) TC92: 1500 psi @ 20.6-25.2 USgpm (103 bar) @ (77.9-95.3 l/min) TC152L: 2200 psi @ 26.7-32.7 USgpm (152 bar) @ (100.
SETTING FLOW & PRESSURE Now adjust the oil flow on the carrier, so the flow meter reads: TC51L/FC: 8-12 USgpm (30-45 l/min) TC51H/FC: 12-18 gpm (44-68 l/min) TC71: 13-17 USgpm (49-63 l/min) TC71FC: 13-22 gpm (49-83 l/min) TC92: 18-24 USgpm (68-91 l/min) TC152L: 25-31 USgpm (95-117 l/min) TC152H: 35-43 gpm (132-163 l/min) TC301: 35-43 USgpm (132-163 l/min) TC301H: 50-61 gpm (189-231 l/min) Note: Better compaction rates occur at higher flows.
START-UP Carrier oil should be clean and in accordance with the manufacturer's recommendations. After mounting the compactor on the boom and connecting the lines, bleed all air from the hydraulic system. Initially pump grease to the pins in the bracket until it oozes out around the pins. Then grease with 10-15 shots daily. Check torque of bolts and fasteners at installation and again after the first 10 hours of operation.
OPERATION Compaction of Materials BTI compactors achieve material compaction by using centrifical force and vibration to displace air and water pockets in the material. Compaction performance depends on 3 items: • Type and size of material being compacted • Moisture content of the material • Depths of lifts being compacted Use a short trial of the compactor to determine the optimum depth of lift and speed of boom travel to achieve the required density.
OPERATION Shut off the compactor and lift it into the air to a new position, or using minimum boom down-force slide the compactor along the ground. Avoid dragging the compactor's plate across the material surface ('ironing') while the motor is running. Forces exerted on the compactor by 'ironing' can cause premature failure.
OPERATION Shut-off Compactor Before Lifting When compaction is complete, shut off compactor before lifting it from the ground. Do not pound the ground with the compactor. Do not start in the middle of an un-compacted area. Always start at the edge, near a solid wall, bank, or a previously compacted area.
OPERATION Maintenance- Every 40 Hours of Operation Check hoses for wear and leaks, replace and tighten as required. The eccentric housing is filled with gear oil. This oil must be changed after the initial 50 hours. Then change oil every year. Use 80W90 gear oil. Do not overfill the oil reservoir. Check the rubber isolators for cracks or fatigue. Clean away any soil and material that has built up in this area. Check that mounting pins and bushings are receiving lubrication.
PRODUCT WARRANTY 1. BREAKER TECHNOLOGY INC. Company (hereinafter referred to as "BTI") warrants this product against defects in materials and workmanship for a period of twelve (12) months or 2000 hours from the date of installation, or 18 months from the date of shipment, whichever comes first. This warranty does not cover o-rings, seals, fittings, hoses, or other items considered normal wear items. These are covered by the LimitedWarranty period of thirty (30) days.
BRACKET OPTIONS Bolt-On Rigid Top Mount: Standard equipment on TC51, TC71, & TC301 Bolt-On QA Non-Swivel Top Mount: Available as an option on the TC71 QA Swivel Top Mount: Standard equipment on TC92 & TC152. Optional Bolt-On on the TC71.
COMPACTORS BTI Compactors COMPACTORS BTI Compactors 2 TC51L Compactor Low Flow 4 TC51H Compactor High Flow 6 TC71FC Compactor Flow Control 8 TC71H Compactor High Flow 10 TC92 Compactor 12 TC152L Compactor Low Flow 14 TC152H Compactor High Flow 16 TC301L Compactor Low Flow 18 TC301H Compactor High Flow 20 TC 1
COMPACTORS BTI Compactors 2
COMPACTORS BTI Compactors ITEM 1 3 4 6 7 8 9 10 11 PART No. TC51L TC51H TC71FC TC71H TC92 TC152L TC152H TC301L TC301H DESCRIPTION Compactor Low Flow ( Page 4 ) Compactor High Flow ( Page 6 ) Compactor Flow Control ( Page 8 ) Compactor High Flow ( Page 10 ) Compactor ( Page 12 ) Compactor Low Flow ( Page 14 ) Compactor High Flow ( Page 16 ) Compactor Low Flow ( Page 18 ) Compactor High Flow ( Page 20 ) When Ordering, Give Part No., Part Name, Model & Serial No. 3 QTY.
TC51L Compactor Low Flow 4
TC51L Compactor Low Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART No. DESCRIPTION 350-0007 1800424 1801470 650-8780 350-0002 650-8795 1008414 1008453 650-8796 1800301 1009497 1912007 1001856 1008798 1912296 1802063 1912132 1941002 1009487 1932008 H405-HHH-020 Upper Weldment Cap (not shown) 210292-8 JIC Cap Pipe Plug 0.75 NPT SOC. HD Bearing Housing Lower Weldment Eccentric Assembly Bearing Retaining Ring Bearing Housing Fitting (2062-10-8) Hydraulic Motor Bolt 3/8" NF X 1" GR.
TC51H Compactor High Flow 6
TC51H Compactor High Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART No. DESCRIPTION 350-0007 1800424 1801470 650-8780 350-0002 650-8795 1008414 1008453 650-8796 1800301 1009488 1912007 1001856 1008798 1912296 1802063 1912132 1941002 1009487 1932008 H405-HHH-020 Upper Weldment Cap (not shown) 210292-8 JIC Cap Pipe Plug 0.75 NPT SOC. HD Bearing Housing Lower Weldment Eccentric Assembly Bearing Retaining Ring Bearing Housing Fitting (2062-10-8) Hydraulic Motor Bolt 3/8" NF X 1" GR.
TC71FC Compactor Flow Control 8
TC71FC Compactor Flow Control ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PART No. DESCRIPTION 360-0002 1008925 220-2708 1912020 1932014 1941004 360-0003 220-2713 1008936 1008935 1800849 220-2707 1912009 1001856 1008798 1800571 1800288 1009505 1912128 1001857 1802251 1800418 1912009 1001856 1009520 1800175 1801470 H409-KKK-025 H410-KKK-023 360-0110 Upper Body Isolator Bearing Housing 0.50NC X 1.5 HHCS Bolt GR.8 .50 NC ESNA Locknut Flat Washer .
TC71H Compactor High Flow 10
TC71H Compactor High Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART No. DESCRIPTION 360-0002 1008925 220-2708 1912271 1932014 1941004 360-0003 220-2713 1008936 1008935 1800849 220-2707 1912009 1001856 1008798 1800571 1800288 1009505 1912128 1001857 1800080 1800418 1801470 H409-KKK-025 H410-KKK-023 360-0110 Upper Body Isolator Bearing Housing Grade 8 Bolt .50 NC ESNA Locknut Flat Washer .
TC92 Compactor 12
TC92 Compactor ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 PART No.
TC152L Compactor Low Flow 14
TC152L Compactor Low Flow ITEM 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PART No. H408-LLL-021 H408-LLL-026 1800943 1010709 1912097 1001857 1800086 1800419 1001858 1007783 1007784 1941015 1912290 1912138 1001768 1912086 1932020 1002182 650-8593 380-0021 650-8659 650-8592 380-0027 1801470 1801980 1800947 650-8589 DESCRIPTION Hose Assembly Hose Assembly Fitting 2062-12-16 Motor c/w Check Valve Bolt 1/2" NF X 1 1/4" GR.
TC152H Compactor High Flow 16
TC152H Compactor High Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PART No. H408-LLL-021 H408-LLL-026 1800292 1800943 1010710 1912097 1001857 1800086 1800419 1001858 1007783 1007784 1941015 1912290 1912138 1001768 1912086 1932020 1002182 650-8593 380-0021 650-8659 650-8592 380-0027 1801470 1801980 1800947 650-8589 DESCRIPTION Hose Assembly Hose Assembly Fitting 2062-16-16 Fitting 2062-12-16 Motor c/w Check Valve Bolt 1/2" NF X 1 1/4" GR.
TC301L Compactor Low Flow 18
TC301L Compactor Low Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART No. 390-0002 390-0015 1010710 1800087 1800292 1800943 1912097 1001857 1800419 1912046 1001858 1932052 1800947 1801855 1801470 1006919 1006920 650-8527 1007828 1006886 650-8525 650-8526 H405-LLL-023 H405-LLL-033 DESCRIPTION Saddle Weldment Eccentric Housing Motor c/w Check Valve Fitting 2021-20-16 Fitting 2062-16-16 Fitting 2062-12-16 Bolt 1/2" NF X 1 1/4" GR.8 Nordlock Washer Set M12 Fitting 210292-16 .
TC301H Compactor High Flow 20
TC301H Compactor High Flow ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART No. 390-0002 390-0015 1010711 1800090 1800292 1800943 1912097 1001857 1800419 1912046 1001858 1932052 1800947 1801855 1801470 1006919 1006920 650-8527 1007828 1006886 650-8525 650-8526 H405-LLL-023 H405-LLL-033 DESCRIPTION Saddle Weldment Eccentric Housing Motor c/w check valve Fitting 2021-20-20 2021-20-20 Fitting 2062-16-16 Fitting 2062-12-16 Bolt 1/2" NF X 1 1/4" GR.
COMPACTORS BTI Compactors NUMERICAL INDEX Part Number Description Page 1001531 1001768 1001856 1001857 Bearing Nordlock Washer Set Nordlock Washer Set Nordlock Washer Set 1001858 1002182 1006886 1006919 1006920 1007783 1007784 1007793 1007794 1007828 1008414 1008453 1008798 1008925 1008935 1008936 1009487 1009488 1009497 1009505 1009520 1009833 1010709 1010710 1010711 1800080 1800086 1800087 1800090 1800115 1800175 1800288 1800289 1800292 1800301 1800418 1800419 1800424 1800571 1800676 1800849 1800943
COMPACTORS BTI Compactors NUMERICAL INDEX Part Number Description Page 1932008 1932014 1932015 1932020 1932052 1941002 1941004 1941015 220-2707 220-2708 220-2713 350-0002 350-0007 360-0002 360-0003 360-0110 370-0023 370-0030 380-0021 380-0027 390-0002 390-0015 650-8525 650-8526 650-8527 650-8589 650-8592 650-8593 650-8618 650-8619 650-8620 650-8641 650-8659 650-8780 650-8795 650-8796 COMPACTORS H405-HHH-020 H405-KKK-014 H405-LLL-023 H405-LLL-033 H408-KKK-022 H408-LLL-021 H408-LLL-026 H409-KKK-025 H410-KK
COMPACTORS BTI Compactors ALPHABETICAL INDEX Description Part Number Page BTI Compactors Compactor Compactor Flow Control Compactor High Flow Compactor High Flow Compactor High Flow Compactor High Flow Compactor Low Flow Compactor Low Flow Compactor Low Flow COMPACTORS TC92 TC71FC TC152H TC301H TC51H TC71H TC152L TC301L TC51L 2 12 8 16 20 6 10 14 18 4 AI 1
COMPACTORS BTI Compactors .375" Flat Washer .50 NC ESNA Locknut .75 Hardened Washer .75NC X 2.5 HH Bolt GR.8 0.50NC X 1.5 HHCS Bolt GR.8 0-Ring Bearing Bearing Bearing Bearing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Bearing Housing Motor Side Bolt Bolt Bolt .375 NC X 1.250" Gr 8 Bolt 0.625" NC X 1.5" GR.8 Bolt 1/2" NC X 1" GR.8 Bolt 1/2" NF X 1 1/4" GR.8 Bolt 3/4" NC X 3" LG. GR.8 Bolt 3/8" NC X 1 1/2" GR.
COMPACTORS BTI Compactors Locknut 3/4"-0.750 NC NT-8419 Locknut .
SOLON FACILITY 30625 Solon Industrial Drive, SOLON OHIO, 44139 U.S.A. PH. 440-542-3720 FAX. 440-542-3721 RIVERSIDE FACILITY 3464 DURAHART ST. RIVERSIDE,CALIF. 92507 U.S.A. PH. 909-369-0878 FAX. 909-369-8281 THORNBURY FACILITY 35 ELGIN ST., THORNBURY,ONT. N0H 2P0 CANADA PH. 519-599-2015 FAX.
